Differential

Differential

Special tools, testers and auxiliary items required

• Slide hammer-complete set (VW 771)

• Socket (27 mm) (3257)

• Torque wrench (VAG 1331)

• Internal puller (Kukko 21/5)

• Removing and installing is possible with the transmission installed.

• The differential can be removed and installed without removing the selector mechanism, input shaft, pinion shaft and bearing housing. These components must be removed if the differential needs to be adjusted.

• Inspect polygon bearings for visible damage.

• The polygon bearings can only be replaced together with the flange shaft.

• If the polygon bearings do not run smoothly with the flange shaft removed, this does not necessarily indicate that the bearings are faulty. A test for noisy bearings can only be performed with the bearings installed.

• A spacer ring is installed between the polygon bearing and the differential sun wheel on flange shafts with 30 mm spline diameter, refer to => [ Flange shaft assembly ] , - Item 4 -.

• Adjustment work is required when replacing the parts marked with 1). Table of adjustments, refer to => [ Adjustment Table ] Adjustment Table.

1 Transmission housing 1)

2 Oil seal

• Removing (left side), refer to => [ Removing flange shaft oil seal (left side) ]

• Installing (left side), refer to => [ Installing flange shaft oil seal (left side) ]

• Removing (right side), refer to => [ Removing flange shaft oil seal (right side) ]

• Installing (right side), refer to => [ Installing flange shaft oil seal (right side) ]

3 Circlip

• Replace.

• Removing and installing, refer to => [ Removing and installing circlip ]

4 Spacer ring

• Is only installed on flange shafts with a spline diameter of 30 mm.

• Remove with Internal puller 30 to 37 mm, e.g. (Kukko 21/5).

• Installing, refer to => [ Installing spacer ring ]

5 Flange shaft

• Removing (left side), refer to => [ Removing flange shaft (left side) ]

• Removing (right side), refer to => [ Remove right flange shaft ]

• Drive in with drift (VW 295).

• Flange shaft assembly, refer to => [ Flange shaft assembly ]

6 Differential with crown wheel 1)

• Disassembling and assembling, refer to => [ Differential ] Differential.

7 O-ring

• Always replace.

• Lubricate with gear oil.

8 Cover for final drive 1)

9 TORX bolt, 20 Nm + an additional 90°1/ 4 turn

Removing flange shaft (left side)

- Remove flange shaft (left side); by securing puller (T10037) to cover for final drive - arrow -.

Remove right flange shaft

- Remove flange shaft (right side); by securing puller (T10037) to transmission housing - arrow -.

Removing and installing circlip

- Clamp flange shaft in vise, using jaw protectors. Use new circlip - A - to press old circlip out of groove in flange shaft.

Installing spacer ring

- Drive new spacer ring in onto stop; do not tilt ring when doing this.

Flange shaft assembly

1. Flange shaft

2. Needle bearing (polygon bearing)

3. Spacer ring

4. Spacer ring - installed on shafts with 30 mm spline diameter

5. Circlip

• The needle bearing (polygon bearing) does not turn easily when the flange shaft is removed. This does not indicate that the bearing is defective.

Removing flange shaft oil seal (left side)

- Pry out flange shaft oil seal using an assembly lever.

Installing flange shaft oil seal (left side)

- Lightly oil outer circumference of new seal.

- Drive in new flange shaft oil seal using driver ( 2062); keep seal straight when installing.

• Insertion depth: 5.50 ± 0.15 mm below top of cover.

• Pack space between sealing lip and dust lip half-full with sealing grease (G 052 128 A1).

- Drive flange shaft in with needle bearing drift ( VW 295).

Removing flange shaft oil seal (right side)

- Pry out flange shaft oil seal - arrow - using an assembly lever.

Installing flange shaft oil seal (right side)